Three-piece disposable undergarment with stretchable crotch member

ABSTRACT

A disposable undergarment includes a front body panel having a pair of opposite first side edges, a first terminal edge and a first cut edge spaced from the first terminal edge and defining a first wave pattern and a rear body panel having a pair of opposite second side edges, a second terminal edge and a second cut edge spaced from the second terminal edge and defining a second wave pattern. A crotch member includes at least one stretchable component having an elastic material connected to the front and rear body panels and stretchable in at least one direction. A first maximum rise of the front body panel is aligned with and spaced apart from a second maximum rise of the rear body panel in a non-overlapping relationship. The crotch member is aligned with and overlaps the first and second maximum rises of the front and rear body panels respectively.

This application is a divisional of U.S. application Ser. No.10/452,340, filed Jun. 2, 2003, which is a continuation-in-part of U.S.application Ser. No. 10/261,805, filed Oct. 1, 2002, now U.S. Pat. No.6,979,380, and also is a continuation-in-part of U.S. application Ser.No. 10/325,500, filed Dec. 19, 2002, the entire disclosures of which arehereby incorporated herein by reference.

BACKGROUND

The present invention relates generally to disposable undergarments, andin particular, to a three-piece undergarment having a folded,stretchable crotch member and to the method for the manufacture thereoffrom a nested front and rear body panel web.

Disposable undergarments can be configured in many different forms. Forexample, disposable absorbent garments can be configured as a pant-type,pull-on garment, or as a diaper-type product that is drawn up betweenthe legs and fastened about the waist with various fastening systems.Often, absorbent garments include an outer cover, which forms at least apart of a body panel that is secured around the waist of the user. Inaddition, the outer cover typically extends along a crotch region of thegarment.

Often, the outer cover is made from a single piece of material, with legopenings cut therein, for example by die cutting. The material from theleg cut out, which can account for as much as 20-30% of the total areaof the outer cover, typically is waste material, which must be disposedof or recycled. In addition, the size of the leg openings formed by adie cutter in a conventional one-piece outer cover is typically fixed.As such, it can be expensive and time consuming, and reduces the overallflexibility of the manufacturing line, to switch dies and alter theprocess to manufacture different size garments.

In response to this problem of waste, some garments are configured withfront, rear and crotch sections formed from a single web that is dividedinto two nested halves, as disclosed for example in U.S. Pat. No.5,858,151 and Japanese Patent Application 03-176053 A. However, the websof the U.S. Pat. No. 5,858,151 have overlapping crotch portions that aredirectly secured one to the other. Accordingly, the overall rise of thegarment is not readily varied to accommodate different size users, andthe range of sizes is limited by the extent of the overlapping regions.

Conversely, the diaper body of Japanese Patent Application 03-176053 Ais positioned over the cut-out portions of a front and back waistband,such that the exposed portion of the waist bands defining in part theleg holes are linear. Instead, the shape of the leg hole is determinedby the cut shape of the diaper body, which produces excess material thatmust be disposed of or recycled.

In addition, the crotch member, which is often configured as anabsorbent insert, is typically not stretchable. Often, thenon-stretchable crotch member is secured across its entire width, whichcan reduce or otherwise impede the elongation of the body panel andthereby adversely affect its ability to conform to the body of the user.

Therefore the need remains for improved methods and assemblies formanufacturing undergarments to reduce the waste of materials whileproviding improved comfort for the user and flexibility in manufacturingdifferent size garments.

SUMMARY

Briefly stated, in one aspect, a method of manufacturing an undergarmentincludes moving a web of body panel material in a longitudinal machinedirection and cutting the web of body panel material along thelongitudinal machine direction to thereby form a rear body panel web anda front body panel web each having a maximum rise and a minimum riserespectively. The maximum rise of each of the rear and front body panelwebs is greater than the minimum rise of a corresponding one of the rearand front body panel webs. The method further includes shifting at leastone of the rear and front body panel webs in the longitudinal machinedirection and thereby aligning the maximum rises of the rear and frontbody panel webs. The method further includes aligning a crotch memberwith the maximum rises of the rear and front body panel webs andconnecting the crotch member to the front and rear body panels. Thecrotch member includes at least one stretchable component including anelastic material.

In one embodiment, the cutting of the web of body panel material alongthe longitudinal machine direction includes forming a substantiallysinusoidal pattern defining the maximum and minimum rises of each of therear and front body panel webs.

In one embodiment, the front and rear body panel webs are cut along thelateral cross direction proximate the minimum rise of each of the frontand rear body panel webs. Also in one embodiment, the crotch member isfolded.

In another aspect, a die is used to cut the web of body panel material.In one embodiment, the method includes forming a cut edge along each ofthe front and rear body panel webs, wherein the cut edges of the frontand rear body panel webs have a first and second shape respectively. Inone embodiment, the first shape is different than the second shape.

In another aspect, the wave pattern defining the cut edges of the frontand rear body panel webs is not symmetrical relative to a centerlineextending in the longitudinal machine direction. In particular, thecurve defining the cut edge on one side of the centerline has adifferent shape than the curve defining the cut edge on the other sideof the centerline. In one example, the curves, if continuous on bothsides of the centerline, would have a different wavelength.

In another aspect, one embodiment further includes elongating the web ofbody panel material in the longitudinal machine direction before cuttingthe web of body panel web. In this way, the pitch of the garment can beeasily changed simply by varying the amount of elongation introducedinto the web before the web is cut.

In yet another aspect, one embodiment of the method further includesvarying a gap formed between the maximum rises of each of the rear andfront body panel webs. In this way, the overall rise of the garment canbe easily changed simply by varying the gap.

In various embodiments, elastic elements are positioned along one ormore of the outer lateral edges of the inner cut edge of one or more ofthe webs.

In various embodiments, the stretchable crotch member is formed of anelastic/stretchable material. In one particular embodiment, one or bothof a top sheet and backsheet, with a retention portion disposedtherebetween, are stretchable and include an elastic material.

In another aspect, a method includes stretching at least one of the backsheet and top sheet. In yet another aspect, a method includesinstructing a user on the user of a disposable undergarment is provided.

The various aspects provide significant advantages over other disposableundergarments and methods. For example and without limitation, thenested body panels of one embodiment maximize the area of body coveragewhile minimizing and virtually eliminating the amount of waste material.In addition, the stretchable crotch member can be stretched with thebody panels to conform to the body of the user. In addition, the elasticmaterial of the crotch member allows the crotch member to stretch andretract, further improving the fit of the garment.

The foregoing paragraphs have been provided by way of generalintroduction, and are not intended to limit the scope of the followingclaims. The presently preferred embodiments, together with furtheradvantages, will be best understood by reference to the followingdetailed description taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a system for manufacturing anabsorbent garment.

FIG. 2 is a plan view of a web of body panel material being cut along alongitudinal machine direction.

FIG. 3 is a plan view of a front and rear body panel web with aplurality of absorbent inserts being applied thereto.

FIG. 4 is a plan view of one embodiment of an absorbent garment in anunfolded configuration.

FIG. 5 is a plan view of another embodiment of an absorbent garment inan unfolded configuration.

FIG. 6 is a plan view of a web of body panel material being cut along alongitudinal machine direction.

FIG. 7 is a plan view of a front and rear body panel web separated inthe cross direction and aligned in the machine direction.

FIG. 8 is a garment having a front and rear body panel web formed fromthe webs shown in FIG. 7.

FIG. 9 is a plan view of one embodiment of an absorbent garment in anunfolded configuration.

FIG. 10 is a cross sectional view of the absorbent garment shown in FIG.9 taken along line 10-10.

FIG. 11 is a cross sectional view of the absorbent garment shown in FIG.9 taken along line 11-11.

FIG. 12 is a cross-sectional view of the absorbent garment shown in FIG.9 taken along line 12-12.

FIG. 13 is a load v. strain graph for an exemplary stretchable materialFIG. 14 is a load v. strain graph for a second exemplary stretchablematerial.

FIG. 15 is a load v. strain graph for an exemplary non-stretchablematerial.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

It should be understood that the term “longitudinal,” as used herein,means of or relating to length or the lengthwise direction 500. The term“laterally,” as used herein, means situated on, directed toward orrunning from side to side. The term “first direction” generally refersto a path, line or course rather than a vector, and includes and appliesequally to opposite orientations along the path, line or course,including for example and without limitation movement along a path, lineor course in both directions (as indicated by the bi-directional arrowsassociated with the longitudinal and lateral directions 500, 502 in FIG.9). Likewise, the term “second direction” generally refers to a path,line or course rather than a vector (not orientation dependent), andincludes for example and without limitation movement along a path, lineor course in both directions. In one example, the first direction isdefined by and refers to one of the longitudinal and lateral directions,while the second direction refers to the other of the longitudinal andlateral directions.

The term “bodyside” should not be interpreted to mean in contact withthe body of the user, but rather simply means the side that would facetoward the body of the user, regardless of whether an undergarment isactually being worn by the user and regardless of whether there are ormay be intervening layers between the component and the body of theuser. Likewise, the term “garment side” should not be interpreted tomean in contact with the garments of the user, but rather simply meansthe side that faces away from the body of the user, and therefore towardany outer garments that may be worn by the user, regardless of whetherthe undergarment is actually being worn by a user, regardless of whetherany such outer garments are actually worn and regardless of whetherthere may be intervening layers between the component and any outergarment.

The term “machine direction” means the direction of flow as the variousmembers and webs progress along the fabrication line and process. Itshould be understood that various separate members or webs can each betraveling in a machine direction, but with the various machinedirections not necessarily being parallel or oriented in the samedirection. For example, a first component such as a web may be travelinga first machine direction, which is substantially perpendicular to thetravel of another component, such as an absorbent insert, in a secondmachine direction.

The term “cross direction” means the direction substantiallyperpendicular to the machine direction.

The term “downstream” means that one item is positioned more closely tothe output or finished product end of the machine and/or processrelative to another item. Conversely, the term “upstream” means that anitem is positioned more closely to the input end of the machine orprocess relative to another item. For example, the output end isdownstream of the input end, and vice versa, the input end is upstreamof the output end.

The phrases “removeably attached,” “removeably attaching,” “removeablyconnected,” “removeably engaged,” “releasably attached,” “releasablyconnected,” or “releasably engaged,” and variations thereof, refers totwo or more elements being connected or connectable such that theelements tend to remain connected absent a separation force applied toone, both or all of the elements, and where the elements are capable ofbeing separated upon the application of a separation force. The requiredseparation force is typically beyond that encountered while wearing theabsorbent garment.

The phrases “fixedly secured,” “fixedly engaged,” “fixedly attached,”“fixedly connected,” and variations thereof, refers to two or moreelements being connected or connectable such that they are notdisconnected or otherwise separated, and are not intended to beseparated or disconnected, during the normal operation and use of theabsorbent garment.

The term “web” refers to a continuous stream of material, whether madefrom one or more layers or substrates, and regardless of whether it mayhave non-continuous, discrete items disposed thereon.

The terms “connecting,” “coupled,” “attached,” and “secured,” andvariations thereof, broadly covers two or more items being directlyconnected one to the other, or by way of one or more intervening membersor components.

Referring to FIGS. 4, 5 and 9, an undergarment 2 includes a first, frontbody panel 4 and a second, rear body panel 6. The term “body panel”refers to the portion(s) of the undergarment, whether made of one ormore layers or substrates or of one or more pieces or components, thatis/are fitted circumferentially around at least the waist region of theuser, including for example the user's lower back, buttock, hips andabdomen. The first and second body panels each have an inner, bodysidesurface 10 and an outer, garment side surface 12. The first, front bodypanel 4 has a first edge 14 forming a crotch portion 16 and leg openingportion 18 and a second terminal edge 20 which, in one embodiment, islinear but can assume other shapes. Likewise, the second, rear bodypanel 6 has a first edge 22 forming a crotch portion 24 and a legopening portion 26 and a second terminal edge 28, which is shown linearbut can assume other shapes. Each of the first and second body panelshas an outboard side edge 30, 32 formed along the outer periphery of theopposite side portions of the first and second body panel. It should beunderstood that the outboard side edges of the front and rear bodypanels can have the same or different lengths relative to each other.

Referring to FIG. 5, one or more, and in one embodiment a plurality,meaning two or more, elastic elements 36 are secured to each of thefirst and second body panels. In preferred embodiment, a plurality ofelastic elements are spaced across substantially the entire waistportion of the front and rear body panel 4, 6, although they may bespaced across a lesser length. For example, elastic elements can extendalong the upper waist portion and along the lower terminal edge definingin part a leg opening 34.

In one embodiment, the front body panel has a “non-elasticized” areawherein there are no elastic elements, or other elastic or elastomericbacking members, incorporated therein or making up any portion of thethickness or cross-section of the body panel at that area. It should beunderstood, that in an alternative embodiment, one or more separatewaist bands, with or without elastic elements, can be secured to one orboth of the rear and front body panels, preferably along the upperterminal edges 20, 28 thereof. Likewise, one or more separate leg bandscan be secured to one or both of the rear and front body panels alongthe leg open portions 18, 26 adjacent the leg openings 34.Alternatively, one or both of the body panels can be formed without anyelastic elements as shown in FIG. 4.

The various waist and leg elastic elements can be formed from rubber orother elastomeric materials. One suitable material is a LYCRA® elasticmaterial. For example, the various elastic elements can be formed ofLYCRA® XA Spandex 540, 740 or 940 decitex T-127 or T-128 elasticsavailable from E.I. duPont De Nemours and Company, having an office inWilmington, Del.

Referring to FIGS. 10 and 12, each body panel 4, 6 is preferably formedas a composite, or laminate material, otherwise referred to assubstrates or laminates, with an elastic core 136 sandwichedtherebetween. In one embodiment, the elastic core 136 is made of anelastomeric film or nonwoven elastic or stretchable material includingfor example but not limited to styrenic copolymers of polyisoprene,polybutadiene or polyolefin, copolymers of polyolefins, natural orstyrene butadiene rubber, polyurethanes, polyamides, polyesters, andco-extrusions/blends of the aforementioned materials. The elastic corecan be formed as a membrane or from a plurality of elastic strands, asdescribed above. In one embodiment, two or more layers 40 are bonded tothe elastic core 136, and/or each other, with various adhesives, such ashot melt, or by other techniques, including for example and withoutlimitation ultrasonic bonding and heat pressure sealing. In oneembodiment, the two layers are made of a non-woven material such as aspunbond material, a bonded carded material or other known materials. Inthis way, the body panels are made of a stretchable/elastic material.

As used herein, the interchangeable terms “stretchable” and “elastic,”and variations thereof, refer to a material that can elongate or deform(stretch) in response to the application of a tensile force undercertain test conditions herein defined below, and upon removal of thetensile force have a length that is less than about 128% of the originallength, which corresponds to hysteresis of less than about 28%. Thus, astretchable or elastic material can be stretched and upon relaxing thematerial, will tend to resume its original shape. As used herein,“extensible” materials are those materials having a length of greaterthan about 128% of the original length when elongated and relaxed undercertain test conditions herein defined below, which corresponds to ahysteresis of greater than about 28%.

It should be understood that the body panels can be made of a singlelayer or substrate of non-woven material, a bi-layer substrate made ofnon-woven materials without an elastic core, or more than two layers orsubstrates. Of course, it should be understood that other knitted orwoven fabrics, non-woven fabrics, elastomeric materials, polymer films,laminates and the like can be used to form one or more of the body panellayers. The term “non-woven” web or material, as used herein, means aweb having a structure of individual fibers or filaments that areinterlaid, but not in an identifiable manner and without the aid oftextile weaving or knitting, as in a knitted or woven fabric.

In one embodiment, the body panel material can be secured to the elasticcore, such as an elastomeric layer or elastic strands or ribbons, whichhave been elongated and retracted, such that the material is gatheredwhen the elastic element(s) are relaxed. Alternatively, the material canbe gathered and laminated to non-elongated elastic elements. In onepreferred embodiment, the body panel includes a gathered elasticlaminate made from nonwoven base sheets bonded with elongated elasticelements sandwiched therebetween.

In various preferred embodiments, the body panel material may besubstantially permeable to air or substantially impermeable to air. Thebody panel material also may be substantially liquid-permeable orsubstantially liquid-impermeable. In particular arrangements, the bodypanel material may be substantially nonelastomeric. In other aspects,the body panels can include an elastomeric material that iselastomerically stretchable at least along one or both of the lateralarticle width and the longitudinal article length. Examples of suchelastomeric composite materials can include a continuous filamentstretch bonded laminate (CFSBL), a vertical filament laminate (VFL),neck-bonded-laminate (NBL), a stretch-bonded-laminate (SBL), anecked-stretch bonded laminate (NSBL) or a necked-thermal laminate, orthe like, as well as combinations thereof. Exemplary CFSBL, NBL, SBL,and NSBL materials are described in U.S. Pat. Nos. 5,226,992, 4,981,747,4,965,122, 5,336,545, 5,385,775, 5,414,470, 4,720,415,4,789,699,4,781,966, 4,657,802, 4,652,487, 4,655,760, 5,116,662 and5,114,781, and 6,323,389, all of which are hereby incorporated herein byreference. Exemplary VFL materials are described in U.S. ProvisionalPatent Application Ser. No. 60/204,307, filed May 15, 2000 and entitled“Method and Apparatus for Producing Laminated Articles,” and PCTapplication WO 01/88245 A2, both assigned to Kimberly-Clark Worldwide,Inc., the Assignee of the present application, with the entiredisclosures of both being hereby incorporated herein by reference. Suchlaminates can provide an improved combination of cloth-like feel andelastomeric stretchability. The body panels can be composed of materialsthat are elastic or elastomeric and exhibit biaxial stretchcharacteristics or lateral/longitudinal stretch characteristics, orwhich are extensible composites. Additional waist and leg elasticelements can be added to, but are not necessarily required by, the bodypanels.

In one embodiment, the body panel material is extensible but notelasticized. For example, the body panel can be made of a film ornon-woven that is attached, by way of adhesives or thermal bonding, toan extensible non-woven material. Alternatively, the body panel can bemade of a low modulus film such as ethylene methyl acrylate (EMA).

As shown in the embodiments of FIGS. 9-12, the entirety of the bodypanels 4, 6, and the crotch member 50, are elasticized, such that theentirety of each of the body panels can elongate and conform to the bodyof the user without any substantial spacing between the body panel andthe user's body, and without the attendant bulkiness of anon-elasticized material.

In one embodiment, the body panels are breathable, cloth-like,multi-directional nonwoven laminates with stretch or extensibleproperties. In one embodiment, the non-woven layers are pre-necked, forexample between about 10% and about 80%, in the longitudinal direction,which provides extensibility in the longitudinal direction with minimalforce.

In one embodiment, the body panel members 4, 6 are made of non-wovenlaminates of two layers of longitudinally extensible 0.60 osypolypropylene spunbond material with elongated strands of Lycra® elasticsandwiched between the spunbond layers and thereafter adhesively bonded.In particular, the body panel material is necked in the cross direction.As used herein, the term “necked,” and variations thereof, refers to anymaterial that has been constricted in at least one dimension by applyinga tensioning force in a direction that is perpendicular to the desireddirection of neck-down. Processes that may be used to constrict amaterial in such a manner include, for example and without limitation,drawing processes. The elastics are then elongated in the machinedirection and secured to the body panel material. The elastics are thenallowed to retract so as to gather the necked spunbond material in thelateral (machine) direction thereby creating an elastically gatherednon-woven body panel with longitudinal extensibility. The term “gather,”and variations thereof, as used herein means puckered, or contractedinto folds or wrinkles, which should be understood as includingmicro-pleats.

In this way, the body panel can be elongated in both the longitudinaland lateral direction to conform to the body of the user when thegarment is applied thereto. In particular, as the user pulls the garmentup over their hips, the non-woven laminate body panels stretch in thelateral direction while the leg regions of the front and rear bodypanels conform to the crotch and body lines of the user. At the sametime, the body panel material extends in the longitudinal direction toconform to the buttocks and stomach of the user. The extensibility ofthe body panels follows the natural curvature of user's body to provideconformance thereto. As the body panel extends in the longitudinaldirection, the spacing between the laterally extending elastic elements,incorporated in one embodiment, will increase.

The body panel non-woven material is preferably substantiallyhydrophobic, which may optionally be treated with a surfactant orotherwise processed to impart a desired level of wettability andhydrophilicity. In one particular embodiment of the invention, the bodypanel is a nonwoven, wire-weave spunbond polypropylene fabric composedof about 1.6 denier fibers formed into a web having a basis weight ofabout 0.6 osy. One suitable non-woven material is the Corinth 0.60 osy,1.6 dpf wireweave, nonwettable Metallocene (EXXON ACHIEVE 2854 PP)spunbond material manufactured by Kimberly-Clark Corporation, theAssignee of the present application.

The crotch member 50 of the various undergarments connecting the frontand rear body panels 4, 6 can be folded such that the side edges 30, 32of the front and rear body panels 4, 6 are aligned, whereinafter theycan be fixedly secured at a seam to form the leg opening 34. The seamcan be formed by bonding, sewing or otherwise attaching the side edges.Alternatively, the product can remain “open,” wherein the body panelsare releasably secured with one or more fastening members as explainedbelow.

In one embodiment, the garment includes a combination of side edges thatare secured to form a seam and fastening members that allow the fit ofthe undergarment to be adjusted. For example, in one embodiment,fastening members are preferably attached to the front body panel andextend inboard relative to the outboard side edge of the front bodypanel from an attachment location, which is preferably spaced inboardfrom the side edge. A landing member can be formed on or secured to thebody panel to receive a refastenable portion of the fastening member.One or more lines of weakness can be provided along the front or rearbody panel such that one or both of the body panels are breakable. Thelines of weakness can comprise a perforation or other series of cuts, athinning, breakage or separation of material, or a strip of a differentkind of material bridging portions of the body panel that is more easilytorn or broken than the other material thereof, which allow a user orthe manufacturer to separate portions of the body panel. For example,the undergarment can be broken along the lines of weakness after thegarment is applied to a user, or beforehand. In one embodiment, thefastening members are secured to the garment-side surface of the bodypanel.

It should be understood that, in other embodiments, the fasteningmembers can be secured to the rear body panel and engage the front bodypanel or, conversely, can be secured to the front body panel and engagethe rear body panel, preferably along at least a portion that is notelasticized. In one embodiment, the fastening members are fixedlysecured to the outer, garment-side surface of the front and/or rear bodypanels, and releasably engage the outer, garment-side surface of thefront and/or rear body panels, although it should be understood that thefastening members could be fixedly secured to an inner body-side surfaceof front and/or rear body panels and releasably engage an inner,body-side surface of the front and/or rear body panels.

When incorporated into a disposable absorbent undergarment, thefastening members can include a refastenable portion, such as an arrayof hook members, adhesives, such as pressure sensitive adhesives,buttons, zippers, snaps and other releasable and reattachable fasteningdevices. In various embodiments, the fastening member includes one, twoor more than two tab members. In one embodiment, the fastening memberscomprise a carrier member, which is preferably fixedly secured to theside portions of the front body panel with adhesive bonds, sonic bonds,thermal bonds, pinning, stitching or other known types of attachment. Inalternative embodiments, the fastening members can be fixedly secured tothe rear body panel or to one or both of the front and rear body panels,for example, at the seam, as explained above.

Referring to the embodiments of FIGS. 4-5 and 9-12, the crotch member 50is formed as a separate subassembly connected to either the bodyside orgarment side surface 10, 12 of the body panel members 4, 6. In eitherembodiment, the crotch member 50 has first and second opposed terminalend edges 60, 62. The crotch member 50 bridges the gap between theterminal edges 14, 22 of the body panels 4, 6 and is connectedrespectively to those body panels at attachment locations 88. The crotchmember 50 that overlaps the body panels or body chassis member can beminimally attached thereto with an attachment having a width of betweenabout 10% and about 100% of the width of the absorbent insert. Forexample, the crotch member can be attached to the body panels along thelongitudinal side edges of the crotch member, or alternatively along acenterline such that the edges of the absorbent insert are not attachedto the body panels or body chassis. In another embodiment, the entiretyof the portion of the crotch member that overlaps the body panels can beattached thereto. The crotch member can be secured to the body panelswhen they are in a stretched or unstretched condition.

The attachment location can extend along the entire length of theoverlapping portion of the crotch member, along only a portion of thelength, or at a discrete point, for example proximate midway between theends 60, 62 of the crotch member. In another embodiment (not shown), theattachment location can be formed from a plurality of discreteattachment locations spaced longitudinally along the centerline. Inother alternatives, the terminal edges of the crotch member 50 can beattached to the body panels, or the crotch member can be secured to thebody panels along the terminal crotch edges 14, 22 thereof.

In one embodiment, shown in FIGS. 9-12, the crotch member is configuredas an absorbent insert 50, which includes a substantially liquidpermeable top sheet 64, or liner, and a substantially liquid impermeableback sheet 66. A retention portion 70 is disposed or sandwiched betweenthe topsheet and the backsheet, which are connected. It should beunderstood that the term “absorbent insert” refers to any material orassembly capable of absorbing liquids or bodily exudates, and may beformed from a single material or component, for example a retentionportion, or can be formed as a composite of several components. Itshould also be understood that the term “crotch member” refers to anymember of any material, including for example and without limitationthose described herein with respect to the body panels and absorbentinserts, and is no limited to absorbent inserts and/or materials. Forexample, the crotch member may be made of one or more layers of anon-woven material. It should further be understood that when the crotchmember does not include an absorbent material, it can still be used inconjunction with various disposable absorbent pads such as adultincontinent and/or feminine pads so as to improve the performance andcomfort of those pads by maintaining them in close proximity to the bodyof the user.

Referring to FIGS. 1-9, the top sheet 64, back sheet 66 and othercomponents of the absorbent insert can be joined for example withadhesive bonds, sonic bonds, thermal bonds, pinning, stitching or anyother attachment techniques known in the art, as well as combinationsthereof. For example, a uniform continuous layer of adhesive, apatterned layer of adhesive, a sprayed pattern of adhesive or any arrayof lines, swirls or spots of construction bonds may be used to join thetopsheet and backsheet, or any of the other components described herein.

In one embodiment, one or more crotch elastic members 38 are sandwichedbetween the top sheet 64 and backsheet 66 along the side edges thereof.The elastic members 38 can extend the entire longitudinal extent of theabsorbent insert, or along only a portion thereof.

Additional layers, including for example, a liquid acquisition anddistribution layer 72, also referred to as a surge or transfer layer,are also preferably incorporated into the absorbent insert. In oneembodiment, the transfer layer does not run the entire length of theabsorbent insert and is shorter than the retention portion.

In one embodiment, the retention portion 70, transfer layer 72 and othercomponents, such as tissue layers, are free floating (unattached)between the back sheet 64 and the top sheet 66, which are secured alongonly the peripheral edges thereof. Alternatively, the retention portion70, transfer layer 72 and other components are minimally attached to oneor both of the back sheet 66 and top sheet 64. For example, theretention portion can be secured to the back sheet along an attachmentlocation positioned along the longitudinal centerline 108 of theretention portion. Alternatively, or in combination with the back sheetconnection, the transfer layer or retention portion can be minimallyattached to the top sheet. In this way, the retention portion 70,transfer layer 72 and other components do not impede or substantiallyaffect the lateral stretchability and extensibility of the absorbentinsert 50 and in particular the top sheet and back sheet, at least oneof which is secured to the body chassis.

In another alternative embodiment (not shown), the retention portion issecured along the centerline at a point midway between the two ends ofthe retention portion. In this embodiment, the retention portion alsodoes not restrict or impede the stretchability and extensibility of theabsorbent insert, and in particular the top sheet and back sheet, in thelateral or longitudinal directions 500, 502.

In other embodiments, the top sheet is indirectly joined to thebacksheet by affixing the topsheet to intermediate layers, such as thesurge layer or retention portion, which in turn is affixed to thebacksheet. The absorbent insert also may include barrier cuffs, orleakage control shields, formed along the opposite longitudinallyextending edges of the absorbent composite.

In one embodiment, the back sheet 66 is a stretchable, elastic, liquidimpervious member. Alternatively, the back sheet may be liquidpermeable, e.g., when an additional barrier layer is used with theretention portion. In one embodiment, shown in FIGS. 9-12, the backsheet 66 is a laminate structure made of a stretchable, elasticmaterial, such as an elastomeric film 80, which is laminated to anextensible non-woven material layer 82. It should be understood that thebacksheet can be formed from a single layer or substrate or more thantwo layers or substrates. The backsheet can be stretchable in both thelateral and longitudinal direction, or be stretchable in one directionand extensible in the other.

The backsheet 66 prevents various bodily fluids and exudates fromwetting or otherwise contaminating various bedding or outer garmentsworn by the user over the absorbent garment. The backsheet can be madeof the same materials described above in connection with the bodypanels. In one embodiment, the backsheet can include a film, which canbe made of the various materials described above.

The backsheet may include a micro-porous, “breathable” material whichpermits gases, such as water vapor, to escape from the absorbent garmentwhile substantially preventing liquid exudates from passing through thebacksheet. For example, the breathable backsheet may be composed of amicroporous polymer film or a nonwoven fabric which has been coated orotherwise modified to impart a desired level of liquid impermeability.For example, a suitable microporous film can be a PMP-1 material, whichis available from Mitsui Toatsu Chemicals, Inc., a company havingoffices in Tokyo, Japan; or an XKO-8044 polyolefin film available from3M Company of Minneapolis, Minn. The backsheet may also be embossed orotherwise provided with a pattern or matte finish to exhibit a moreaesthetically pleasing appearance.

In various embodiments, where a component, such as the backsheet isconfigured to be permeable to gas while having a resistance and limitedpermeability to aqueous liquid, the liquid resistant component can havea construction which is capable of supporting a selected hydrohead ofwater substantially without leakage therethrough. A suitable techniquefor determining the resistance of a material to liquid penetration isFederal Test Method Standard FTMS 191 Method 5514, 1978, or anequivalent thereof.

In one embodiment, the backsheet is sufficiently impermeable to liquidand semi-liquid materials to substantially prevent the undesired leakageof waste materials, defined as exudates, including for example urine andfeces. For example, the backsheet member can desirably support ahydrohead of at least about 45 centimeters (cm) substantially withoutleakage. The backsheet member can alternatively support a hydrohead ofat least about 55 cm, and optionally, can support a hydrohead of atleast about 60 cm, or more, to provide improved benefits.

In one example, the backsheet can be composed of a necked fiber, acreped fiber, a micro-pleated fiber, polymer films or the like, as wellas combinations thereof. The fabrics may be woven or nonwoven materials,such as spunbond fabrics. One example of a suitable extensible materialis a 60% necked, polypropylene spunbond having a basis weight of about1.2 osy.

Three types of backsheet materials were tested forstretchability/extensibility.

EXAMPLE 1 VFL Material

The material is a three-ply laminate having inner and outer facinglayers of 0.46 ounces per square yard (osy) polypropylene spunbondmaterial (Kimberly-Clark Delta white polypropylene spunbond) and amiddle layer of 10 grams per square meter (gsm) Kraton® 666 elastomerstrands (3 mm apart) elongated to 4.5 to 5.5 times. The three piecelaminate is adhesively laminated with 2.5 gsm Bostik Findley H2096adhesive. This VFL material was tested as explained below and as shownin FIG. 13.

EXAMPLE 2 Necked Liner Laminate

The material is made of a two-ply laminate consisting of a softco-extruded film laminated to a necked nonwoven material. In particular,the material is made of a layer of 0.4 ounces per square yard (osy)polypropylene spunbond material (Kimberly-Clark Delta whitepolypropylene spunbond) that was necked 35% (to 65% of initial width) toa final basis weight of 0.6 osy and laminated to a Pliant Film XP-86000.7 mil (CaCO3 metallocene Dow Affinity and Dowlex 2035 LLDPEco-extruded film). This material was tested as explained below and asshown in FIG. 14.

EXAMPLE 3 Necked Liner

The material was made of a nonwoven 0.4 ounces per square yard (osy)polypropylene spunbond material (Kimberly-Clark Delta whitepolypropylene spunbond) that was necked 65% (to 35% of initial width) toa final basis weight of 0.7 osy. This material was tested as explainedbelow and as shown in FIG. 15.

Referring to FIGS. 13-15, force/strain curves are shown for each of thethree exemplary backsheet materials. The stress/strain curves weredeveloped from a test to determine the “stretchability” of“extensibility” of the material, as those terms are defined above. The“Stretchability/Extensibility” test is as follows:

Test Procedure (One-Cycle Tensile Test (without hold time)):

-   -   1. A 2 inch wide by 5 inch long specimen was cut from a sheet of        sample material. The stretchable direction of the material was        in the length direction of the specimen, which is also the test        direction.    -   2. The one-cycle tensile test was conducted on a tensile tester        (Model: Synergie 200 available from MTS) located in a room where        the temperature was maintained at 23 degrees C. and with a        relative humidity at 50%.    -   3. The distance between the lower and upper jaws of the tensile        tester were set at 3 inches.    -   4. The jaws were clamped onto the specimen.    -   5. The moving (upper) jaw was activated to travel at a constant        rate of 5 inches/minute away from the stationary (lower) jaw.        The moving jaw was stopped at an extension of 1.8 inches (60%        extension).    -   6. The moving jaw then returned immediately to its initial        starting position at a rate of 5 inches/minute.    -   7. The load v. % strain for the tension and retraction cycle was        recorded on a computer equipped with TestWorks Version 3.10        software program available from MTS.

As shown in FIGS. 13 and 14, the VFL and Necked Liner Laminate materialsare stretchable as that term is defined above, meaning that they have ahysteresis strain of less than about 28%, or a length of less than about128% of the original length. As shown in FIG. 15, the Necked Linermaterial has a hysteresis of greater than about 28%, or a length greaterthan about 128%, such that it is extensible rather than stretchable asthose terms are defined above.

In various constructions, the top sheet 64 can include various woven ornonwoven materials and laminates, which can be stretchable orextensible. In one embodiment, the top sheet 64, shown in FIGS. 9-12, isan extensible material, such as a necked spunbond material. For example,the topsheet can be composed of a meltblown or spunbonded web of desiredfibers, and may also be a bonded-carded web. For example, the topsheetand liner can be made of a substantially hydrophobic material, and thehydrophobic material may optionally be treated with a surfactant orotherwise processed to import a desired level of wettability andhydrophilicity. In one particular embodiment of the invention, thetopsheet is a nonwoven, spunbond polypropylene fabric composed of about2.8-3.2 denier fibers formed into a web having a basis weight of about22 gsm and density of about 0.06 gm/cc. The fabric can be surfacetreated with an operative amount of surfactant, such as about 0.28%Triton X-102 surfactant. The surfactant can be applied by anyconventional means, such as spraying, printing, brush coating or thelike. In another embodiment, the top sheet can also include an elasticmaterial, such that it is stretchable.

The retention portion 70 is made of an absorbent material, which can beany material that tends to swell or expand as it absorbs exudates,including various liquids and/or fluids excreted or exuded by the user.For example, the absorbent material can be made of airformed, airlaidand/or wetlaid composites of fibers and high absorbency materials,referred to as superabsorbents. Superabsorbents typically are made ofpolyacrylic acids, such as FAVOR 880 available from Stockhausen, Inc. ofGreensboro, N.C. The fibers can be fluff pulp materials, such asAlliance CR-1654, or any combination of crosslinked pulps, hardwood,softwood, and synthetic fibers. Airlaid and wetlaid structures typicallyinclude binding agents, which are used to stabilize the structure. Inaddition, various foams, absorbent films, and superabsorbent fabrics canbe used as an absorbent material. Various acceptable absorbent materialsare disclosed in U.S. Pat. No. 5,147,343 for Absorbent ProductsContaining Hydrogels With Ability To Swell Against Pressure, U.S. Pat.No. 5,601,542 for Absorbent Composite, and U.S. Pat. No. 5,651,862 forWet Formed Absorbent Composite, all of which are hereby incorporatedherein by reference. Furthermore, the proportion of high-absorbencyparticles can range from about 0 to about 100%, and the proportion offibrous material from about 0 to about 100%. Additionally, highabsorbency fibers can be used such as Oasis type 121 and type 122superabsorbent fibers available from Technical Absorbent Ltd., Grimsby,Lincolnshire, United Kingdom.

The retention portion preferably can be made of a single or dual layerof absorbent material. In one embodiment, the retention portion has anhour-glass shape with enlarged end regions. Alternatively, the retentionportion is substantially rectangular. The retention portion can includea folded or multi-layered configuration. Likewise, the entire absorbentinsert can have a folded configuration, with various folds formed fromone or more of the backsheet, top sheet, retention portion or othercomponents. The retention portion can have a length substantially equalto, or slightly shorter than, the length of the absorbent insert. Theretention portion can include one or more barrier layers attached to theabsorbent material. In one embodiment, an upper tissue substrate 74 isdisposed adjacent the retention portion. Alternatively, a lower tissuesubstrate 75 can be disposed adjacent an opposite side of the retentionportion, or the tissue can completely envelope the retention position.

Referring to FIGS. 3-5 and 9, the opposite garment side of the endregions of the absorbent insert 50, and in particular, the outer,garment side surface of the back sheet 66, are connected to the bodysidesurface of the first and second body panels 4, 6 at attachment locations88. It should be understood that in an alternative embodiment, theabsorbent insert, for example the body side thereof, can be connected tothe garment side surface of the first and second body panels asexplained above. It should be understood that the absorbent insert 50can be secured using any of the methods of attachment described above,including for example various adhesives, stitching or other bondingmethods. The absorbent insert can be secured to the body panels with anyconfiguration of attachment lines, swirls, patterns, spots, etc., or canbe a full and continuous attachment therebetween.

In operation, the user applies the undergarment to their body, whetherby way of pulling it up around their waist as a pant-like garment or byway of fastening it about their waist with fasteners as a diaper-likegarment. As the garment is applied or fitted to the body of the user,the front and rear body panels 4, 6 are elongated from a firstcondition, preferably relaxed, to a second condition, preferablyelongated, in at least one direction, preferably the lateral direction502. Of course, the body panel members can also elongate in thelongitudinal direction 500 from the crotch to the waist. In oneembodiment, one or both of the body panels 4, 6 is elongated in alateral direction 502 between about 20% and about 300%, in anotherembodiment between about 50% and about 200%, and in another embodimentbetween about 100% and about 150%, as it is applied to the user. Thebody panel members are elongated by virtue of a tensile force beingapplied thereto as they conform to the body of the user.

As one or both of the body panel members 4, 6 are elongated, with theattendant application of a tensile force, the absorbent insert, whichincludes in one embodiment an extensible top sheet 64 and astretchable/elastic back sheet 66, stretches or elongates with the bodypanels. The back sheet can be elongated in one embodiment between about20% and about 150%, in another embodiment between about 40% and about125% and in another embodiment between about 50% and about 100%. Since,in one embodiment, the retention portion 70 is free floating, oralternatively is minimally attached to the stretchable top sheet and thestretchable/elastic back sheet, e.g., along the longitudinal center line108, the retention portion 70 does not restrict the elongation of theback sheet 66 and top sheet 64, or the attached body panels 4, 6.

In another aspect, the manufacturer or retailer of the afore-describedabsorbent garments provides instructional information to the user, forexample by way of textual or pictorial indicia on the packagingmaterials, about how the garment works. For example, the manufacturer orretailer can explain to the end user the advantages of thestretchable/elastic absorbent insert, and the resultant ability of thebody panels to freely conform to the body of the user withoutrestriction from the retention portion, thereby improving theconformance and fit of the garment.

Referring to FIGS. 1-8, the method for fabricating one or moreembodiments of the aforedescribed refastenable absorbent garment isillustrated. Referring to FIGS. 1, 2, 6 and 7, a web 72 of body panelmaterial is cut in a longitudinal machine direction 74 to form a frontand rear body panel web 76, 78. Preferably, the web 72 is cut in asinusoidal wave pattern, which should be broadly interpreted as apattern having peaks 54, 154 and valleys 56, 156, with the patterngenerally defined by a pitch P and an amplitude A, A1. The pattern canbe formed of undulating curves or wave patterns, or can include or bemade entirely of various linear portions.

Each body panel web includes an outer lateral edge 80, 82 and an innercut edge 84, 86. In one embodiment, shown for example in FIG. 3, theinner cut edges 84, 86 of the front and rear body panel webs correspond,or mate such that they have the same shape and amplitude. In such anembodiment, no waste material is generated.

In an alternative preferred embodiment, shown in FIGS. 6-8, the wavepattern defining the first and second cut edges 84, 86 has a first andsecond shape 102, 104 formed on opposite sides of a wave baseline 100,which extends in the longitudinal machine direction approximately halfway between the peaks 54, 154 and valleys 56, 156 of the cut edges. Inthis embodiment, the first shape 102 is different from said second shape104, with each shape having a different curvature. In particular, thefirst shape 102 has a first wavelength L1 and the second shape 104 has asecond wavelength L2. Preferably, the first wavelength L1 is greaterthan the second wavelength L2. In this way, as shown in FIG. 8, thefront body panel 4 can be provided with a different shape than the rearbody panel 6. For example, the undergarment can be configured as a thongshaped undergarment with a relatively narrow rear body panel 6.

In another preferred embodiment, a die cutter 100 is used to cut theweb. The die cutter is configured to form inner cut edges 84, 86 on thefront and rear body panels having different shapes and amplitudes A, A1,as shown for example in FIG. 2. In such an embodiment, a minimal amountof waste material is generated, but it allows for the front and rearbody panels to be specifically shaped to conform to the body of theuser. For example, the shape of the rear body panel web 78 cut edge 86can be provided with lesser amplitude A1 than the amplitude A of thefront body panel web 76. In this embodiment, a minimal amount of wastematerial 42 is produced. In one embodiment, one of the body panels isformed with a wave pattern, or substantially sinusoidal cut edge, whilethe other is configured with a straight cut edge. In various alternativeembodiments, the cut edges can be formed by an oscillating cutter,slitters, water jets, lasers and other known cutting devices.

In the preferred embodiment, each of the front and rear body panel webs76, 78 has a maximum rise (Max R), measured at the peak 54, 154 andforming crotch portion lobes 16, 24 (along the centerline of thegarment), and a minimum rise (Min R), measured at the valley 56, 156.The term “rise,” as used herein, means the measured distance between twoedges, for example the outer edge 80, 82 and the inner cut edge 84, 86of each of the front and rear body panel webs 76, 78 respectively. Thetotal rise of the garment is measured between the outer edges 20, 28 ofthe front and rear body panels, or body panel webs, after the crotchmember is connected thereto. Preferably, one or both of the front andrear body panel webs are shifted in the longitudinal machine direction,as shown to align the maximum rises, or peaks 54, 154, of the front andrear body panels, which also results in the alignment of the minimumrises, or valleys 56, 156, of the front and rear body panels. In apreferred embodiment, the maximum rises, defining lobes 16, 24 of theabsorbent garment, have a profile in plan view that extends outwardlyrelative to the waist edge 20, 28. As shown in FIG. 1, a first andsecond conveyor 102, 104 can simply be spaced apart so as to provide fora longer travel for one of the front and rear body panel webs 76, 78.

Referring to FIGS. 1 and 2, the front and rear body panel webs 76, 78are also separated, or shifted, outwardly relative to one another in thelateral cross-direction 94 so as to form a gap 88 between the cut edges84, 86 of the front and rear body panel webs 76, 78 at the maximum riseformed at the respective peaks 54, 154. In various embodiments, thespacing between the cut edges at the maximum rise of the respectivefront and rear body panels (i.e., the closest spacing between the frontand rear body panels) is preferably between about 1% and about 90% ofthe total rise of the garment, more preferably between about 10% andabout 60% of the total rise of the garment, and most preferably betweenabout 20% and about 40% of the total rise of the garment. In addition,in various embodiments, the spacing between the cut edges at the maximumrise of the respective front and rear body panels is preferably betweenabout 10 mm and about 800 mm, more preferably between about 50 mm andabout 500 mm, and most preferably between about 100 mm and about 300 mm.In an alternative embodiment, the cut edges and the crotch portions ofthe front and rear body panels overlap, and can be secured one to theother. In such an embodiment, the panels can be separated slightly, orcan simply be shifted in the longitudinal direction without any lateralseparation.

In one embodiment, the front and rear body panel webs 76, 78 areseparated such that no portions of either web overlap each other. Forexample, and referring to FIG. 1, in one embodiment, a first pair ofrollers 106 can be angled or twisted to laterally spread the front andrear body panel webs 76, 78 a first amount before they are shifted inthe longitudinal machine direction. A second pair of rollers 108 can beangled or twisted to laterally spread the front and rear body panel webs76, 78 a second amount after they are shifted in the longitudinalmachine direction. Of course, it should be understood that the front andrear body panels can be first shifted in the longitudinal machinedirection the desired amount and then separated in the lateral crossdirection the entire desired amount, or they can also be first separatedin the lateral cross direction the entire desired amount and thenshifted in the longitudinal machine direction. In another embodiment,the portions of the lobes or peaks of the body panels overlap eachother.

After the body panel webs 76, 78 are aligned and separated, regardlessof the order thereof, a plurality of crotch members 50, for exampleabsorbent inserts, are positioned in the lateral cross direction so asto bridge the gaps 88 between the body panel webs 76, 78 at successivepeaks 54, 154 or lobes 16, 24 where the maximum rises of the body panelwebs are aligned at the centerline of the absorbent garment. It shouldbe understood that the term “gap” as used herein includes a “zero”distance between the respective cut edges, wherein the cut edges abutbut do not overlap. The crotch members 50 are secured to the body panelwebs 76, 78 as explained above. It should be understood that the crotchmembers 50 are secured in one embodiment to a bodyside surface 90, 92 ofthe body panel webs 76, 78, although they can also be secured to thegarment side thereof as explained above with respect to FIGS. 9-12. Inone embodiment, the crotch members, for example the absorbent inserts,are assembled offline and are then applied to the front and rear bodypanel webs 76, 78 as those webs are carried by a construction drum 110.

As shown in FIG. 1, the crotch member is preferably rotated using anoffset cam action rotator 112. The rotator includes a plurality oftransfer segments 126, which can have a vacuum applied thereto, thatengage the crotch member 50. Coupler arms 127 connect the transfersegments and a drive ring. The coupler arm 127 includes a cam end havinga cam follower that follows the profile of a cam mechanism. The profileof the cam mechanism can be readily changed to change the desired speedoutput and pitch of the crotch member. In one preferred embodiment, therotator is configured to accelerate the crotch member. If the successivecrotch members 50 are separated by a perforation, the transfer segment126 breaks the perforation as it engages one crotch member and movesaway from the next crotch member, which is engaged by a next transfersegment 126. The rotator rotates the end portion of the transfersegment, preferably approximately 90 degrees, about a radial axis, suchthat the crotch member is oriented in the machine direction as describedabove as the transfer segments are rotated about a horizontal axis 128.Alternatively, the landing material and fastener material are cut andseparated by the transfer segments. The rotator, and the method for theuse thereof, is further disclosed in U.S. Pat. Nos. 5,761,478,5,759,340, and 6,139,004, and U.S. patent application Ser. No.10/038,766, entitled “Apparatus For Applying Discrete Parts to A MovingWeb,” filed Jan. 2, 2002, all of which are assigned to Kimberly-ClarkWorldwide, Inc., the Assignee of the present application, and the entiredisclosures of all of which are hereby incorporated herein by reference.Alternatively, the subassembly can be rotated using a revolving transferroll as shown and described in U.S. Pat. No. 4,608,115, which isassigned to Kimberly-Clark Worldwide, Inc., the Assignee of the presentapplication, and which is hereby incorporated herein by reference in itsentirety.

Referring to FIGS. 1 and 4, after the crotch members 50 are secured tothe body panel webs 76, 78 across the gap 88, the assembly is conveyedon a conveyor 114 to a helical folder 116, wherein the undergarments,and in particular the crotch members, are successively folded such thatthe front and rear body panel webs 76, 78 are positioned in anoverlapping, or overlying relationship, preferably with the outer edges80, 82 aligned. In various alternative embodiments, the body panel webs76, 78 can be secured, for example by bonding, along a lateral crossdirection at the area of minimum rise, or valleys 56, 156 to form theside seam 48. The front and rear body panel webs 76, 78 are then cutalong the lateral cross direction along the seam 48 to form a pluralityof discrete disposable undergarments, each having a front and rear bodypanel 4, 6. Alternatively, the front and rear body panel webs 76, 78 canbe first cut at the area of minimum rise, or valleys 56, 156, and thecrotch member 50 thereafter folded. Various refastenable fasteningmembers can be applied to the front and rear body panels 4, 6 or frontand rear body panel webs 76, 78 before or after the various cutting andfolding operations. In yet another preferred embodiment, as explainedabove, the undergarment can be configured with side seams which securethe front and rear body panels, and refastenable fastening members,which bridge lines of weakness formed in one or the other of the bodypanels.

The elastic elements 36 are preferably incorporated into the web 72 ofbody panel material prior to cutting the web 72 to form the front andrear body panel webs 76, 78. If leg elastics are desired, preferablythey are integrated into the web 72 along a pattern that will follow thecut edge 84, 86 on each of the front and rear body panel webs 76, 78. Ofcourse, it should be understood that the elastics could be secured tothe body panel webs after they are formed by the die cutter, or othercutting operation. In addition, the elastics can be non-continuous andintermittently spaced along the longitudinal direction such that theyare incorporated along only the leg opening portions 18, 26 of the bodypanel webs and body panels.

The pitch (P) of the undergarment can be easily and quickly adjustedwithout the need to change over to new dies. The term “pitch” as usedherein means the distance between any two adjacent things in series, andin particular between the valleys 56, 156 or side edges 30, 32 of thefinished undergarment. In particular, the web 72 of body panel materialis simply stretched or elongated various predetermined amounts before itis cut to form the front and rear body panel webs 76, 78. For example,the largest waist/hip size is provided when the web 72 of body panelmaterial is introduced into the cutting operation, or die cutter, withno elongation or stretch in the longitudinal machine direction. Thesmallest waist/hip size is provided when the web 72 of body panelmaterial is elongated or stretched to its maximum capability, such thatafter the cutting operation, the front and rear body panel webs 76, 78retract to form a garment having a smaller pitch (P) between thevalleys. In one preferred embodiment, the elongation of the body panelmaterial is between about 20% and about 400%, in a more preferredembodiment the elongation is between about 50% and about 300%, and in amost preferred embodiment the elongation is between about 100% and about200%. The final size or pitch of the undergarment is also determined bythe process and positioning of the side seams, and the distancetherebetween.

The rise (R) of the undergarment, measured between the outer edges 20,28, also can be easily and quickly adjusted without the need to changeover to new dies. In particular, the front and rear body panel webs aresimply spaced apart in the lateral cross direction varying amounts,preferably with the gap being less than the length of the crotch member.For example, for a smaller garment having a lesser rise, the front andrear body panel webs 76, 78 are spaced closer together, with a smallergap 88 or by overlapping the body panels, than for a garment having agreater rise.

Preferably, the same crotch member 50 can be used in any of thegarments, regardless of the pitch and rise. In this way, the overallsimplicity and efficiency of the system and method is greatly improved,and there is no need to maintain inserts of different sizes ininventory, or to provide manufacturing capabilities to produce differentsize inserts. Indeed, the preferred embodiment of the method providesfor a system of manufacturing a three-piece disposable undergarment withminimal waste, while providing flexibility to manufacture different sizegarments at minimal cost.

In another use, the folded configuration of the absorbent insert (notshown) in combination with the absorbent insert being attached to thegarment side of the body panels, allows for the absorbent insert toexpand outwardly as it is insulted by the user. This expansion iseffected without affecting the fit to the body of the user. In addition,the lobes of the body panels 4, 6, which extend over portions of theabsorbent insert 50, provide a physical barrier between the absorbentinsert and the body of the user.

Although the present invention has been described with reference topreferred embodiments, those skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention. As such, it is intended that the foregoingdetailed description be regarded as illustrative rather than limitingand that it is the appended claims, including all equivalents thereof,which are intended to define the scope of the invention.

1. A disposable undergarment comprising: a front body panel comprising apair of opposite first side edges, a first terminal edge and a first cutedge spaced from said first terminal edge and defining a first wavepattern, said first wave pattern further defining a first maximum riseand a first minimum rise of said front body panel along a firstdirection, wherein said first maximum rise is greater than said firstminimum rise such that said first cut edge further defines a firstamplitude of said first wave pattern, and wherein said opposite firstside edges are spaced along a second direction, said second directionbeing substantially perpendicular to said first direction, said oppositefirst side edges defining a first pitch of said first wave pattern, andwherein said front body panel is stretchable in at least said seconddirection; a rear body panel comprising a pair of opposite second sideedges, a second terminal edge and a second cut edge spaced from saidsecond terminal edge and defining a second wave pattern, said secondwave pattern further defining a second maximum rise and a second minimumrise along said first direction, wherein said second maximum rise ofsaid rear body panel is greater than said second minimum rise such thatsaid second cut edge defines a second amplitude of said second wavepattern, and wherein said opposite second side edges are spaced alongsaid second direction, said opposite second side edges defining a secondpitch of said second wave pattern, and wherein said rear body panel isstretchable in at least said second direction; and a crotch membercomprising at least one stretchable component comprising an elasticmaterial connected to said front and rear body panels and stretchable inat least said second direction, wherein said first maximum rise of saidfront body panel is aligned with and spaced apart from said secondmaximum rise of said rear body panel in a non-overlapping relationship,and wherein said crotch member is aligned with and overlaps said firstand second maximum rises of said front and rear body panelsrespectively.
 2. The disposable undergarment of claim 1 wherein saidfirst and second wave patterns are substantially the same.
 3. Thedisposable undergarment of claim 1 wherein said crotch member comprisesa back sheet connected to a top sheet and a retention portion disposedbetween said back sheet and said top sheet, wherein at least one of saidback sheet and said top sheet are stretchable and comprise said elasticmaterial.
 4. The disposable undergarment of claim 3 wherein each of saidfront and rear body panels comprise one or more elastic elementsdisposed adjacent said first and second terminal edges and said firstand second cut edges.
 5. The disposable undergarment of claim 3 whereinsaid back sheet is stretchable and comprises said elastic material. 6.The disposable undergarment of claim 5 wherein said back sheet comprisesa laminate comprising a non-woven material and said elastic material. 7.The disposable undergarment of claim 1 wherein said front and rear bodypanels are extensible in said first direction.
 8. The disposableundergarment of claim 1 wherein said crotch member is connected to agarment side surface of each of said front and rear body panels.
 9. Adisposable undergarment comprising: a front body panel comprising a pairof opposite first side edges, a first terminal edge and a first cut edgespaced from said first terminal edge and defining a first wave pattern,said first wave pattern further defining a first maximum rise and afirst minimum rise of said front body panel along a first direction,wherein said first maximum rise is greater than said first minimum risesuch that said first cut edge further defines a first amplitude of saidfirst wave pattern, and wherein said opposite first side edges arespaced along a second direction, said second direction beingsubstantially perpendicular to said first direction, said opposite firstside edges defining a first pitch of said first wave pattern; a rearbody panel comprising a pair of opposite second side edges, a secondterminal edge and a second cut edge spaced from said second terminaledge and defining a second wave pattern, said second wave patternfurther defining a second maximum rise and a second minimum rise alongsaid first direction, wherein said second maximum rise of said rear bodypanel is greater than said second minimum rise such that said second cutedge defines a second amplitude of said second wave pattern, whereinsaid second wave pattern and said first wave pattern have substantiallythe same shape, and wherein said opposite second side edges are spacedalong said second direction, said opposite second side edges defining asecond pitch of said second wave pattern; and a crotch member comprisingat least one stretchable component comprising an elastic materialconnected to said front and rear body panels and stretchable in at leastsaid second direction, wherein said first maximum rise of said frontbody panel is aligned with and spaced apart from said second maximumrise of said rear body panel in a non-overlapping relationship, andwherein said crotch member is aligned with and overlaps said first andsecond maximum rises of said front and rear body panels respectively.10. The disposable undergarment of claim 9 wherein said crotch membercomprises a back sheet connected to a top sheet and a retention portiondisposed between said back sheet and said top sheet, wherein at leastone of said back sheet and said top sheet are stretchable and comprisesaid elastic material.
 11. The disposable undergarment of claim 10wherein said back sheet is stretchable and comprises said elasticmaterial.
 12. The disposable undergarment of claim 11 wherein said backsheet comprises a laminate comprising a non-woven material and saidelastic material.
 13. The disposable undergarment of claim 9 whereineach of said front and rear body panels comprise one or more elasticelements disposed adjacent said first and second terminal edges and saidfirst and second cut edges.
 14. The disposable undergarment of claim 9wherein said front and rear body panels are extensible in said firstdirection.
 15. The disposable undergarment of claim 9 wherein saidcrotch member is connected to a garment side surface of each of saidfront and rear body panels.
 16. The disposable undergarment of claim 9wherein said front body panel is stretchable in at least said seconddirection.
 17. The disposable undergarment of claim 9 wherein said rearbody panel is stretchable in at least said second direction.
 18. Adisposable undergarment comprising: a front body panel comprising a pairof opposite first side edges, a first terminal edge and a first cut edgespaced from said first terminal edge and defining a first wave pattern,said first wave pattern further defining a first maximum rise and afirst minimum rise of said front body panel along a first direction,wherein said first maximum rise is greater than said first minimum risesuch that said first cut edge further defines a first amplitude of saidfirst wave pattern, and wherein said opposite first side edges arespaced along a second direction, said second direction beingsubstantially perpendicular to said first direction, said opposite firstside edges defining a first pitch of said first wave pattern, andwherein said front body panel is stretchable in at least said seconddirection; a rear body panel comprising a pair of opposite second sideedges, a second terminal edge and a second cut edge spaced from saidsecond terminal edge and defining a second wave pattern, said secondwave pattern further defining a second maximum rise and a second minimumrise along said first direction, wherein said second maximum rise ofsaid rear body panel is greater than said second minimum rise such thatsaid second cut edge defines a second amplitude of said second wavepattern, and wherein said opposite second side edges are spaced alongsaid second direction, said opposite second side edges defining a secondpitch of said second wave pattern, and wherein said rear body panel isstretchable in at least said second direction; and a crotch membercomprising at least one stretchable component comprising an elasticmaterial connected to said front and rear body panels and stretchable inat least said second direction, wherein said first maximum rise of saidfront body panel is aligned with and spaced apart from said secondmaximum rise of said rear body panel in a non-overlapping relationship,and wherein said crotch member is aligned with and overlaps said firstand second maximum rises of said front and rear body panelsrespectively, wherein said crotch member comprises a back sheetconnected to a top sheet and a retention portion disposed between saidback sheet and said top sheet, wherein at least one of said back sheetand said top sheet are stretchable and comprise said elastic material,wherein said back sheet is stretchable and comprises said elasticmaterial and wherein said back sheet comprises a laminate comprising anon-woven material and said elastic material.
 19. The disposableundergarment of claim 18 wherein said first and second wave patterns aresubstantially the same.
 20. The disposable undergarment of claim 18wherein said front and rear body panels are extensible in said firstdirection.